Compressed Air Audits using AIRMaster

Abstract

Air compressors are a significant industrial energy user and therefore a prime target for industrial energy audits. The project goal was to develop a software tool, AIRMaster, and supporting methodology for performing compressed air system audits. Seven field audits were conducted to refine the software and methodology as well as assess the savings potential of six common Operation and Maintenance measures. Audit results yielded significant savings with short payback periods. Total estimated savings for the project were 4,056,000 kWh or 49.2% of annual compressor energy for a cost savings of $152,000. Total implementation costs were $94,700 for a project payback period of 0.6 years. Capital benefits of delaying or avoiding the cost of a new compressor might double the energy benefits if a new compressor is being considered. The methodology proved to be a simple and effective audit tool.